Face shield devices and methods

ABSTRACT

Disclosed are improved face shields that comprise a piece of flexible, liquid-impervious, transparent film that has adhered thereto an elongate strip of a liquid-absorbent material. The face shield is adapted to be held in place between the worker&#39;s forehead and the rim of a hat, for example, a baseball cap, painter&#39;s hat or surgical hat. When in place, the liquid-absorbent material contacts the forehead of the worker and helps to hold the face shield in place. In addition, the flexible liquid-absorbing member absorbs perspiration coming from the worker&#39;s forehead. The face shield cantilevers in a self-supporting manner outward and downward from the rim of the hat thereby protecting the worker&#39;s face from deposits of airborne liquid (e.g., airborne liquid such as paint, texture spray, or bodily fluids) or from airborne particulate (e.g., sanding dust). Together with the hat, the face shield of the invention provides protection for both the top of the head and the face of the worker.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 61/201,688, filed Dec. 12, 2008, and entitled FACE SHIELD DEVICES AND METHODS, the disclosure of which is incorporated herein by reference.

FIELD

The invention relates to face shield devices and to methods of using face shield devices to protect a worker's face from airborne liquids and particles.

BACKGROUND

It is often desirable for workers who are working with or around liquid or airborne particulate to wear a protective device to prevent the liquid or particulate from depositing on the face. For example, when painting or applying a liquid coating material to a surface by rolling, brushing, spraying or the like, it is all too common to have the liquid coating spatter and come into contact with the applicator's head and face. This problem is exacerbated when the application of paint or liquid coating material takes place overhead, for example, when painting or texture spraying a ceiling. If care is not taken to protect the head and face from splatter, the applicator must later clean the dried coating from his face and hair. Protection is also desirable since some coating materials include harmful ingredients. In addition to tradesmen, medical personnel also require protection from the splattering of blood or other body fluids that may spread disease. In order to encourage the wide use of face shields (especially in the painting and construction trades) a face shield that is cost-effective, comfortable to wear, easy to mount and adjust, and disposable or easy-to-clean is highly desirable. For example, a face shield that allows the wearer to wear glasses under the face shield or a face shield that absorbs perspiration that may be generated by the wearer is desirable.

SUMMARY

The invention is addressed to the aforementioned need in the art and provides improved face shield devices and methods of protecting a worker's face from airborne liquid and airborne solid particulate.

In one aspect the present invention provides an improved face shield device. The face shield of the invention comprises a piece of flexible, liquid-impervious, transparent film that has adhered thereto an elongate strip of a liquid-absorbent material. The face shield of the invention is adapted to be held in place between the worker's forehead and the rim of a hat, for example, a baseball cap, painter's hat or surgical hat. When in place, the liquid-absorbent material contacts the forehead of the worker and helps to hold the face shield in place. In addition, the flexible liquid-absorbing member absorbs perspiration coming from the worker's forehead. The face shield of the invention cantilevers in a self-supporting manner outward and downward from the rim of the hat thereby protecting the worker's face from deposits of airborne liquid (e.g., airborne liquid such as paint, texture spray, or bodily fluids) or from airborne particulate (e.g., sanding dust). Together with the hat, the face shield of the invention provides protection for both the top of the head and the face of the worker.

In another aspect, the invention provides a method of protecting a worker's face from airborne liquids and airborne particulate, the method comprising the steps of:

(a) providing a face shield comprising a piece of a transparent, flexible, liquid-impervious sheet material;

(b) providing a hat having a rim that can be sized to snugly fit a worker's head; and

(c) positioning a portion of the piece of the sheet material between the rim of the hat and the forehead of the worker so that the face shield is frictionally held therebetween and cantilevers in a generally outward and downward direction to cover at least a portion of the worker's face.

In one embodiment of the method, the face shield is first held in position against the forehead of the worker with the flexible liquid-absorbing member contacting the forehead of the worker. A hat is then put onto the head of the worker so that the face shield is held between the forehead of the worker and the rim of the hat. Once in place, the worker can then manually adjust the face shield into its desired position. When in place, the face shield is held between the rim of the hat and the forehead of the worker.

In another embodiment of the method, the hat is first put onto the head of the worker and the face shield is then inserted between the rim of the hat and the forehead of the worker.

The face shield of the invention is adapted to be held in place between the worker's forehead and the rim of a hat, for example, a baseball cap, painter's hat, or surgical hat. When in place, the flexible liquid-absorbing member contacts the forehead of the worker and helps to hold the face shield in place against the forehead of the worker. The face shield cantilevers in a self-supporting manner in a direction generally outward and downward from the rim of the hat, thereby protecting the worker's face from airborne liquid (e.g., paint or coating splatter or bodily fluids) and from airborne particulate. Together with the hat, the face shield of the invention provides protection for both the top of the worker's head and for the worker's face.

In another embodiment, the invention provides a face shield comprising: a flexible, transparent, liquid-impervious film having an upper edge, a lower edge, and two side edges; a flexible liquid-absorbing member attached to the film proximate to the upper edge; and an elastic band that is attached to the film proximate to the upper edge to form a loop with the film. The elastic band is sized to fit snugly around the worker's head with the flexible liquid-absorbing member positioned against the worker's forehead.

BRIEF DESCRIPTION OF THE FIGURES

The invention will be described further in connection with the attached drawings, wherein like reference numbers have been used to indicate like parts and wherein:

FIG. 1 is a perspective view of an embodiment of a face shield of the invention.

FIG. 1A is a perspective view of an embodiment of a face shield of the invention.

FIG. 2 is a perspective view showing a face shield of the invention worn by a worker.

FIG. 3 is a perspective view of an embodiment of a face shield of the invention.

FIG. 4 is a perspective view of an embodiment of a face shield of the invention worn by a worker.

DETAILED DESCRIPTION

Referring to FIG. 1, an embodiment of a face shield in accordance with the present invention is shown at 10. In the embodiment of FIG. 1, face shield 10 includes a generally rectangular flexible transparent liquid-impervious sheet material 12 having an upper edge 14, a lower edge 16, and opposite side edges 18 and 20. The shape and size of sheet material 12 is not critical, however, it should be large enough to cover a substantial portion of the worker's face. In a preferred embodiment, the sheet material 12 is rectangular in shape. For example, the sheet material 12 may be rectangular and have a width of about 8 inches to about 12 inches along upper and lower edges 14 and 16, and may have a length of about 4 inches to about 10 inches along opposite side edges 18 and 20. In one embodiment, the sheet material 12 is rectangular having a width of about 10 inches and a length of about 6 inches. In some embodiments, face shield 10 has rounded corners 24. Face shield 10 includes flexible liquid-absorbing me 22 that is attached proximate upper edge 14 and contacts the worker's forehead when face shield 10 is worn. Typically, the flexible liquid-absorbing member 22 comprises an absorbent material, for example, a woven or non-woven cloth. In some embodiments, the flexible liquid-absorbing member includes a super-absorbent polymer. The flexible liquid-absorbing member 22 may be attached to the transparent member 12 using any known method including, for example, ultrasonic welding, liquid adhesive, adhesive tape, stitching, or a hook and loop fastener. The liquid-absorbing member 22 is flexible so that face shield 10 can bend to conform to the shape of the forehead of the worker, yet can lie flat when not in use. Advantageously, this allows face shield 10 to be stored and shipped flat.

In embodiments of the invention the flexible, transparent, liquid-impervious sheet material 12 is a polymer film. Representative examples of polymers include polyester, polyolefin (e.g., polyethylene or polypropylene), polyurethane, acrylic, and acetate. In some embodiments, the polymer film comprises polyester. In some embodiments, the polymer film has a thickness ranging from about 1 to about 10 mils, for example, from about 2 to about 5 mils. Other thicknesses may also be useful. The sheet material should be flexible enough to conform to the worker's forehead yet should be rigid enough to support its own weight so that it cantilevers outwardly over the worker's face and maintains a separation from the worker's face when the face shield is in use. In some embodiments, the sheet material may include an anti-fogging coating on the side of the sheet material nearest the worker's face. In some embodiments, the sheet material may include a low surface energy coating (i.e., a “release coating”) on the outer surface of the sheet material (i.e., the surface opposite the worker's face). The low surface energy coating allows the outer surface of the face shield to be more easily cleaned in applications where cleaning and re-use is acceptable.

The face shield 10 of the invention does not include a strap or other device for mounting it over the face of a worker. Rather, the face shield 10 of the invention is held in place with a hat, for example, a baseball cap, painter's hat, or surgical hat. The face shield is held in place by pressure exerted between the worker's forehead and the rim of a hat that the worker is wearing. Referring now to FIG. 2, worker's head 40 is shown fitted with baseball cap 42 and face shield of the invention 10. Baseball cap 42 has crown portion 44 having lower rim 46 that extends around the circumference of worker's head 40. Face shield 10 is frictionally held under crown portion 44 of cap 42 between worker's forehead 48 and rim 46. As shown in FIG. 2, flexible liquid-absorbing member 22 in contact with the worker's forehead 48. Flexible sheet material 12 cantilevers in self-supporting manner in a direction generally outward and downward from rim 46 so that it covers at least a portion of the face 50 of worker 40. Since the sheet material 12 cantilevers outwardly over the worker's face 50, the worker may wear eyeglasses without interference from the face shield. In addition, since the face shield extends outwardly away from the worker's face, the face shield receives substantial airflow under the face shield through open area 52, minimizing the chance for fogging on its interior surface and for heat build-up under the face shield.

In order to wear the face shield 10, the worker first inserts the face shield 10 into the front portion of a cap 42 with the flexible liquid-absorbing member 22 facing away from the front of the hat 42. Holding the face shield 10 and cap 42, the worker then puts the hat on his head such that the face shield is positioned between the worker's forehead 48 and the rim 46 of cap 42. The worker may then adjust the face shield so that the flexible liquid-absorbing member 22 contacts the worker's forehead 48 and so that the face shield is positioned to substantially cover the face 50 of the worker 40.

Alternatively, the worker can first put the cap 42 on his head and then insert the face shield 10 between the rim of the cap 42 and the worker's forehead 48. It may be necessary to leave the rim 46 of the cap 42 slightly loose in order to allow the face shield 10 to be inserted in this manner. After inserting the face shield 10, the rim 46 of the hat can be tightened and the position of the face shield 10 can be adjusted.

In another embodiment, as shown in FIG. 1A, face shield device 10A includes a plurality of sheets 12A-12C of flexible, transparent, liquid-impervious sheet material. In some embodiments, face shield 10A may include from 2 to 10 sheets. Each sheet 12A-12C is releasably attached to the sheet below it in the stack. Specifically, sheet 12A is releasably attached to sheet 12B, and sheet 12B is releasably attached to sheet 12C. The sheets may be releasably attached using any technique that allows the top sheet of the stack to be removed without separating the remaining sheets. Representative attachment techniques include, for example, ultrasonic welding or adhesive. In use, face shield 10A is worn until the outer surface is soiled. In order to clean the face shield, the top sheet of the stack is detached from the remaining sheets to provide a clean surface.

Referring now to FIG. 3 another embodiment of a face shield device 60 is shown. Face shield 60 includes a generally rectangular flexible transparent liquid-impervious sheet material 62 having an upper edge 64, a lower edge 66, and opposite side edges 68 and 70. The shape and size of sheet material 62 is not critical, however, it should be large enough to cover a substantial portion of a worker's face. In a preferred embodiment, the sheet material 62 is rectangular in shape. For example, the sheet material 62 may be rectangular and have a width of about 8 inches to about 12 inches along upper and lower edges 64 and 66, and may have a length of about 4 inches to about 10 inches along opposite side edges 68 and 70. In one embodiment, the sheet material 62 is rectangular having a width of about 10 inches and a length of about 6 inches. In some embodiments, face shield 60 has rounded corners.

Face shield 60 includes an elastic band 80 that is adhered to the sheet material 62 along upper edge 64 thereby forming a loop 82 for securing the face shield around the head of the worker. Elastic band 80 may be made of elastic cloth or stretch bonded laminate. Elastic band 80 is sized to fit snugly around a typical worker's head. Elastic band 80 may be adhered to sheet material 62 using a variety of techniques including, for example, ultrasonic welding, adhesive, stitching, and the like. Face shield 60 further includes flexible liquid-absorbing member 72 that is attached proximate upper edge 64 and contacts the worker's forehead when face shield 60 is worn. Typically, the flexible liquid-absorbing member 72 comprises a woven or non-woven cloth. In some embodiments, the flexible liquid-absorbing member includes a super-absorbent polymer. The flexible liquid-absorbing member 72 may be attached to the transparent member 62 using any known method including, for example, ultrasonic welding, liquid adhesive, adhesive tape, stitching, or a hook and loop fastener. Referring now to FIG. 4, worker 84 is shown wearing face shield 60. As shown, elastic band 80 secures the face shield 60 to the forehead of the worker 84.

Face shield devices of the invention are typically worn until the outer surface of the face shield has been soiled with an unacceptable accumulation of fluid or particulate. The face shield is then removed and either cleaned or discarded.

While the invention has been described in connection with its preferred embodiments, it should be recognized that changes and modifications can be made without departing from the scope of the appended claims. 

1. A face shield adapted to be held in place by pressure exerted between the forehead of a person and the rim of a hat that the person is wearing, said face shield comprising: a flexible, transparent, liquid-impervious film having an upper edge, a lower edge, and two side edges; and a flexible liquid-absorbing member that is affixed to a surface of said film proximate said upper edge; wherein the face shield is sufficiently flexible to conform to the forehead of a person when the upper edge of the film is inserted between the rim of what and the person's forehead with the flexible liquid-absorbing member contacting the person's forehead; and wherein the film is sufficiently rigid when inserted between the rim of a hat and the person's forehead so that the film cantilevers in a self-supporting manner over at least a portion of the person's face.
 2. A face shield comprising: a flexible, transparent, liquid-impervious film having an upper edge, a lower edge, and two side edges; a flexible liquid-absorbing member attached to the film proximate to the upper edge; and an elastic band attached to the film proximate to the upper edge; wherein the elastic band forms a loop for mounting the face shield around a person's forehead.
 3. The face shield of claim 2, wherein the elastic band is made of elastic cloth or stretch bonded laminate.
 4. The face shield of claim 1, wherein the film comprises polyester, polyolefin, polyurethane, acrylic, or acetate.
 5. The face shield claim 1, wherein the film comprises polyester.
 6. The face shield of claim 1, wherein the film comprises polyester having a thickness ranging from about 1 to about 10 mils.
 7. The face shield of claim 1, wherein the flexible liquid-absorbing member comprises a woven cloth or a nonwoven cloth.
 8. The face shield of claim 7, wherein the flexible liquid-absorbing member further comprises a super-absorbent polymer.
 9. The face shield of claim 1, wherein the flexible liquid-absorbing member is attached to the film with an adhesive, tape, or stitching.
 10. The face shield of claim 1, wherein the piece of film is rectangular.
 11. The face shield of claim 10, wherein the piece of film has a length ranging from about 8 inches to about 12 inches and a width ranging from about 4 inches to about 10 inches.
 12. The face shield of claim 1, wherein the flexible, transparent, liquid impervious film comprises a plurality of sheets of film that are releasably attached to one another.
 13. The face shield of claim 12, wherein the film comprises 2 to 10 sheets that are releasably attached to one another.
 14. The face shield of claim 12, wherein the sheets are releasably attached using an adhesive or ultrasonic welding.
 15. A method of protecting a person's face from airborne liquids or airborne solid particulate, the method comprising the steps of: (a) providing a face shield according to claim 1; (b) providing a hat having a rim that can be sized to snugly fit a person's head; and (c) positioning the upper edge of the face shield between the rim of the hat and the person's forehead so that the face shield is frictionally held therebetween and cantilevers in a self-supporting manner over at least a portion of the person's face.
 16. The method of claim 15, wherein the film comprises polyester, polyolefin, polyurethane, acrylic, or acetate.
 17. The method of claim 15, wherein the film comprises polyester.
 18. The method of claim 15, wherein the film comprises polyester having a thickness ranging from about 1 to about 10 mils.
 19. The method of claim 15, wherein the flexible liquid-absorbing member comprises a woven cloth or a nonwoven cloth.
 20. The method of claim 19, wherein the flexible liquid-absorbing member further comprises a super-absorbent polymer.
 21. The method of claim 15, wherein the flexible liquid-absorbing member is attached to the film with an adhesive, tape, or stitching.
 22. The method of claim 15, wherein the piece of film is rectangular.
 23. The method of claim 22, wherein the piece of film has a length ranging from about 8 inches to about 12 inches and a width ranging from about 4 inches to about 10 inches.
 24. The method of claim 15, wherein the flexible, transparent, liquid impervious film comprises a plurality of sheets of film that are releasably attached to one another.
 25. The method of claim 15, wherein the film comprises 2 to 10 sheets that are releasably attached to one another.
 26. The method of claim 25, wherein the sheets are releasably attached using an adhesive or ultrasonic welding. 